Chris Peters EXPERION UNIT OPERATIONS SUITE June · PDF fileIntroduction & Roadmap Chris...

Introduction & RoadmapEXPERION UNIT OPERATIONS SUITEChris Peters

June 19, 2017

Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.

What is Experion Unit Operations Suite (UOS)?

1

Collection of Existing Products (with enhancements)

New DCS Hardware Platform

Modified Licensing Model

Experion PKS

Experion Batch Manager

Procedure Analyst

MES Integration API

REFERNECE FB (LEAP)

ControlEdge UOC

900 Controller

900 UIO

Virtual UOC

Custom Batch Reporting

Golden Batch Tracking

Batch & Continuous View

Third Part Historian

Connector


Unit Operations Suite Development Objectives

2

Deliver offering to meet the needs of the overall Batch markets with specific

emphasis and focus on Pharmaceutical, Specialty Chemicals and Food & Bev

• Modular Control & IO platform for Experion PKS

• S88 (Batch Standard) alignment in automation workflow, usability and

terminology

• Scalable solution (250 IO and up)

• Simplify licensing of Batch Projects

• Optimized for legacy system replacement


What is ControlEdge?

3

The next set of new releases involves our

new ControlEdge™ technology, a next

generation family of controllers using either

the rack-based ControlEdge 900 or

ControlEdge 2020 platform.

In addition to the ControlEdge PLC and

ControlEdge HC900, PAS is introducing

several releases using this compact form

factor.


What is Experion Unit Operations Controller (UOC)?

4

1) ControlEdge 900 Platform with DCS Engine (CEE)

1) Controller (Optionally Redundant)

2) Power Supplies

3) UIO (First Release)

4) Classic IO (Second/Third Release)

5) 6 Rack Options (7th coming soon)

2) Virtual UOC (Digital Twin of UOC, vUOC)

1) Virtual Machine based UOC

Simulation Controller

Batch Engine with Large Memory

Pilot Plant and R&D Facility

Non-critical Applications

Keep the vUOC and UOC as digital twins!


What is Experion Unit Operations Controller (UOC)?

5

•Redundant Controller (Optional)

• Embedded Firewall (no CF9 needed)

•Redundant PS (Optional) 60W (110/240 VAC, 24VDC)

• Ethernet Comms - FTE up and Ring [HSR & DLR] or Star down [PRP]

• IO Racks (4, 8, 12 Slots)

•CEE/Control Builder - Application Development (same as C200/C300)

• Firmware Manager – Management of Firmware

•Operating temperature - 0 to 60°C

•Certifications - CE, UL, CSA & CSA US, RoHS compliant

•Component Level Certifications (Honeywell cabinet not Required)

Unit Operations Controller - Key Features


Honeywell ControlEdge Unit Operations Controller

6

1. Redundant power supply option 60W

(110/240 VAC, 24VDC)

2. PSM Module (optional Power status module)

3. Redundant CPM option (Redundancy can be

added later)

4. SD memory card slot (future use)

5. Support up to 12 IO Cards/Rack (4, 8, 12 Slot Racks)

6. Uplink ports for FTE communications

7. Downlink ports to IO Network (Ring or Star)

8. 16 Channel Universal IO module

Redundant Controller Option

Rack to Rack Redundant

Controller Option in 2018


Controller (CPM) & IO Rack Scanner (EPM)

7

CPM

EPM

FTE

IO & EIPRing Star


I/O Network Support for Ethernet/IP

Ring Network

Total 12 racks

UOC Controller

Turck I/O

First ReleaseRockwell I/O

(Future Release)

900 Series I/O

First Release (R505)Smart MCCs

First Release (R505)


Human Factors

Wide Access IO Door

Plastic doors with a metal hinge - when

opened, enables unobstructed access and

visibility to the terminal blocks and the

paper labels

Faster Wiring and Troubleshooting

Security Cover

Cover prevents

accidental

memory card

ejection and

helps secure

Ethernet cables

in place

Reduce Human

Error


Potential Phase 2 (2018Q2) IO Module Options

New IO Modules Based on Proven Platform Offer Flexibility in System Configuration

10

• Phase 2 IO modules offer multiple

choices and flexibility in system

design to meet specs

• Improves our ability to serve more

applications needing AC/ DC or

sinking/sourcing IO ability

• Improves product fit in Americas

with AC modules for DI and DO

DI

24VDC

DI

120/240 VAC

UAI

TC, RTD, V

DO

24VDC

DO

120/240 VAC

UIO

24VDC


Universal IO HART Support & FDM Integration

HART-enabled UIO with FDM Integration Reduces Solution Cost and Improves Maintenance Tasks

11

• On-board HART Support for all 16 Universal IO

Channels – No Extra Hardware

• Individual Embedded Hart Modem per channel

FDM Integration

• Fast & Accurate Commissioning of Field Devices

- Pre-built templates from FDM

- Easy device configuration, downloads and uploads

• Better Maintenance Decisions

- Simplifies diagnostics

- FDM highlights device specific faults

- More productive (& fewer) site trips

- No need to go into hazardous areas


Why a new platform?


Market Requirements Matrix

Requirements Upstream, Refining,

Petrochem

Pharma, Spec Chem,

Food & Beverage

Certification Body Certification Required Required

Controller Redundancy Required Required

I/O Redundancy Required Rare

Remote I/O Emerging Required

Zone 2 Certification Required Required

Increasing Environmental Specs Emerging Limited

Sequence Application Petrochemical Batch Required

Memory Intensive Applications Rare Required

Third Party I/O System Rare Required


Comparing C300 & UOC

Requirements Upstream,

Refining,

Petrochem

C300 Capability Pharma, Spec

Chem,

Food & Bev

UOC Capability

Certification Body Certification Required CE, UL, CSA & CSA US,

RoHS

In Cabinet

Required Certified Component not

cabinet

CE, UL, CSA & CSA US,

RoHS

Controller Redundancy Required Supported Required Supported

I/O Redundancy Required Supported Rare Not Supported

Remote I/O Emerging Universal Cabinets Required Supported via Ethernet no

cabinet restrictions

Zone 2 Connected Devices Required Supported Required Supported

Increasing Environmental Specs Emerging -40/+55 Deg C Limited Operating temperature 0 to

60°C

Sequence Application PetroChem Batch Experion Sequence Facilities Required Experion Sequence Facilities

Memory Intensive Applications Rare Memory Limited Required Increased Memory Capacity

Third Party I/O System Rare EIP/Profibus/

DeviceNet

Required Supported via EIP & PCDI


Unit Operations Suite Development & Overview

15

• Extension of Experion Batch Manager (with differentiating enhancements) running on the

new ControlEdge Unit Operations Controller

• Target Applications

Continuous / batch applications in Specialty Chemical, Pharmaceutical and Food &

Beverage

• Virtual Controller (vUOC) targeted for Batch Engine & IO Connected Process Applications

• Utilize ControlEdge PLC Hardware

• Announcements at NA (June) HUG in 2017 for Release 1

• Release 1 in Q3 2017


UOS Licensing

Licensing Optimized for Targeted Segments

• Same base license, SCADA license, OPC, etc.

• IO Point (Analog & Discrete) based licensing for UOC based control (server wide)

- Continue Process Point licensing for C200/C300/ACE based control

• Minimal UOC CEE license

- Encourage behavior of purchasing controllers (in alignment with S88)

• Regulatory & Compliance Point to enable QVCS & Electronic Signature

- Match server total IO Point count

• Batch Point (next slide)

• Same product and licensing for Direct and Indirect Channels

16

Model

Number

Model Description Comments

EP-ANLG50 50 Analog IO Point Adder typically 20% to 30% of total IO

EP-DISC50 50 Discrete IO Point Adder typically 70% to 80% of total IO

TC-SWCS90 ControlEdge UOC Process Solver (Valid for

either Embedded or Virtual UOC)

Low price to encourage use of more controllers

TC-RCMP01 50 PT REG COMPLIANCE ADDER

EP-1UOS50 50 T1 Batch Point Adder


UOS Licensing Batch Points

Quick Quote Turnaround!!!

• Batch Points will need to match the total IO Points license (Analog IO

Points + Discrete IO Points)

• Batch Points include all the common components

- Recipe Control Modules

- Class Based Recipes

- Procedure Analyst

- Experion ODBC Connection

- MES Integration API

- Recipe Studio

No need to count or estimate any Batch details other than IO Points!!!

17


Licensing Exercise

18

1) Standard Experion Base License

2) Analog & Discrete Points (assume an 80/20 mix)

1) Analog IO Points = 200 (50 x 4)

2) Discrete IO Points = 800 (50 x 16)

3) CEE License (8 or 9 controllers)

4) Reg & Compliance Points (1000)

5) Batch points (1000)

6) Op Stations (5)

Model Number Description Quantity

EP-DBASE1 Experion Base License 1

EP-ANLG50 50 Analog IO Point Adder 4

EP-DISC50 50 Discrete IO Point Adder 16

TC-SWCS90 ControlEdge UOC Process Solver (Valid for

either Embedded or Virtual UOC)8 or 9

TC-RCMP01 50 PT REG COMPLIANCE ADDER 20

EP-1UOS50 50 T1 Batch Point Adder 20

Flex Station Flex Station 5


IO Points & Simulation

19


REFERENCE Function Block & Simulation

20


Does UOC Suit My Application?

Good Fit

✔DCS Replacements reusing cabinets

✔Applications where space is premium

✔Existing facility with crowded IO rooms

✔In MCCs

✔Custom field mounted JBs

✔Batch Process

✔Small IO Count (500 or less)

✔Large Discrete IO Count

Pharmaceutical, Food & Beverage,

Specialty Chemical, Fine Chemical, Pulp &

Paper

Poor Fit

✖Redundant IO

✖Existing PMIO (any IO Link)

✖CAB Requirements

Upstream & Midstream Oil & Gas, Refining

Large Petrochemical

21


Batch Control / Discrete Control Integrated Options

Experion

Server

Control Execution Environment

Via Control BuilderIEC-61131 Environment

Via ControlEdge Builder

Batch

Production

Plant

Product

Transport

System

Common Operator StationCommon Engineering Station

Unit Operations

Controller

ControlEdge

PLC

Common Field Device Manager

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